Vehicle Wire Harness Packing and Installation Method
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Solution Overview
Problem
The installation of high-voltage wire harnesses in vehicles is cumbersome due to their rounded state during transportation, requiring unwinding and handling, which complicates the process and may lead to moisture intrusion and damage.
Innovation Solution
A wire harness design featuring a flexible first installation part, a sequential installation part, and a packing member that allows the harness to be transported in a compact state, facilitating installation by maintaining the packed state during installation, with a water-tight grommet for moisture prevention and flexible tube parts for easy insertion through vehicle holes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the wire harness is transported in a rounded state in a returnable box, then it is compact for transportation, but it requires unwinding and spreading before installation which complicates the installation process
Solution Approach 1:
The wire harness is pre-assembled with installation parts (connectors, clamps, etc.) already attached in the correct positions and orientations before transportation. This preliminary assembly eliminates the need for complex installation operations after unwinding, allowing the harness to be installed directly in its compacted state or with minimal unfolding.
Solution Approach 2:
The wire harness is divided into multiple bundled groups, each containing conductors with their corresponding installation parts. These segmented bundles can be independently handled and installed, reducing the complexity of manipulating the entire harness at once and facilitating easier installation even when transported in a compact form.
2Ease of operation
If the wire harness is spread out for installation, then it can be properly installed, but it increases the risk of moisture intrusion and damage during handling
Solution Approach 1:
A protective sheath or coating is applied to the wire harness, particularly at the installation parts and conductor surfaces. This flexible protective layer prevents moisture intrusion during handling and installation while allowing the harness to be properly positioned and connected. The sheath can be easily applied without requiring the harness to be fully spread out.
Solution Approach 2:
Installation parts such as connectors, clamps, and sealing elements are pre-assembled and pre-protected before transportation. This preliminary assembly ensures that critical components are already in place and protected, reducing the need to handle and expose the entire harness to potential moisture during the installation process.
3Ease of operation
If the wire harness is handled and unwound from the returnable box, then it can be installed, but the handling process increases the complexity and time required for installation
Solution Approach 1:
The wire harness is pre-assembled with all installation parts (connectors, clamps, fasteners) attached in their final positions before transportation. This preliminary configuration eliminates the need for time-consuming assembly operations during installation, allowing the harness to be quickly positioned and connected at the vehicle.
Solution Approach 2:
Multiple functions are merged into the wire harness design: the conductors, installation parts, protective sheath, and even the returnable box structure are integrated into a single unified assembly. This merging reduces the number of separate handling and assembly steps required, significantly reducing installation time and complexity.
Data Source
AI summary
A wire harness is bent or folded at a position of a flexible part and then set to a packed state by a packing member, and in the packed state, a first installation part is set to a state of being able to be installed in a vehicle.